Thick butt shingle and process of making same



April 5, 1932; H. EMERY THICK BUTT SHINGLE AND PROCESS OF MAKING SAME Filed Dec. 15, 1928 'H/mer/z EMEPY INVENTOR BY 7 jg QN \N WN 0% 3 3 \N aw Q ATTORNEY Patented Apr. 5, 1932 UNITED STATES PATENTOFFICE HARRY ALLEN EMERY, OF ROSELLE PARK, NEW JERSEY, ASSIGNOR TO THE BARRETT COMPANY, OF NEW YORK, N. Y., A CORPORATION OF NEW JERSEY THICK B'U'IE'J.- SHINGLE AND PROCESS OF MAKING SAME Application filed December 15, 1928. Serial No. 326,328.

This invention relates to surfacing materials such as roof or wall surfacings, shingles,

shingle strips and the like, and more particularly to a process for producing tapered shingle strips and tapered shingles, and to such shingles.

An object of this invention is to provide a process that can be practiced'in the usual multi-cylinder paper making machines to produce a sheet of varying thickness transversely of its length. This sheet can then be treated in well known types of roofing machines to produce tapered shingles which simulate in contour the common wood shingle and thick butt shingles. Another object is to produce a surfacing, shingle strip or shingle which affords many advantages over prepared surfacing, as heretofore produced. Heretofore, tapered shingles or shingle strips, or surfacings of varying thickness have been made by molding the waterproof material such as asphalt by means of rollers of the desired contour after the asphalt has been applied to'the felt base, so that the re- 'sultant felt saturated surfacing is given the desired shape. It has also been proposed to fold the asphalt impregnated felt or paper into the desiredshape, leaving the wide end thereof open, thereafter insert through the open end of the folded sheet a filler made up of comminuted inert material and a suitable binder, and then fold the open end to form the desired product.

According to the present invention, a plurality of sheets of varying width are made in the usual multi-cylinder paper making ma chine. These sheets may be made from any suitable material such as wool, cotton or linen rags, straw, hemp, flax or other vegetable fibers, which, when treated as is well known in the art, will product a sheet which can readily be saturatedwith asphalt or. other waterproofing saturants to provide a suitable roofing or other surfacing base. Preferably, the sheets are simultaneously made from like material.

The cylinder molds are deckled i. e. are provided with well known types of dckling devices so that the width of the sheet can be controlled at will.. Two cylinder molds preferably form sheets of, the same width and the wet felts and the cylinder molds being pref erably so arranged that the sheets are fed with the longitudinal center lines in alignment and coinciding when the sheets are superposed. The resultant product comprising a plurality of superposed sheets of different widths is then fed over a suction roll which functions to remove some of the excess moisture and thereafter through suitable pressing rolls and drying devices. There is thus produced a laminated fabric or sheet of maximum thickness along predetermined longitudinal portions and of gradually dimin ishing thickness transversely of the length of the sheet, this fabric is preferably severed along the longitudinal maximum thickened portions forming a sheet which has a gradual taper transversely of its length. The resultant sheets can be wound into rolls for subsequent treatment or may be fed directly to a roofing machine where they are saturated with bituminous material, such as asphalt, pitch or the like, and surfaced with granular or mineral matter such as slate, stone or mica. If desired, the strip of surfacing may besevered transversely' to form tapered or thick butt shingles. l

The present invention comprises a process of producing surfacing material which involves making a plurality of sheets of different widths and uniting the sheets to form a surfacing material, preferably of progressively decreasing thickness "transversely of the length of the sheet, and also relates to the products produced by the practice of this process, i. e. the laminated strip of surfacing material having. the laminae of progressively from the following detailed description taken in connection with the accompanying draw- 7 'in' s, in which-- ig. 1 is a somewhat diagrammatic side elevation of a multi-cylinder paper making machine adapted to practice the present invention; Fig. 2 is a section along the line 22 of Fig. 1 showing a section through the sheet formed in the machine in the stage of operation indicated by the line 22;

Figs. 3, 4, 5 and 6 are sections taken along the lines 33, 44, 5-5 and 6-6,.respectively, corresponding toFig.-2 and showing the position of the sheets at the stages of operation indicated by the lines 3-3, 4-4, 5-5 and6-6, respectively; and

Fig. 7 is a section through a tapered shingle produced from the sheet of Fig. 6.

Referring to the drawings, 1 indicates-the vats or containers of the usual type paper making machine, arranged to contain'the digested material such as wool, cotton or linen rags, straw, hemp, flax or other vegetable fiber from whichthe sheets are made. Cylinder molds 2, 3, 4 and 5 are rotatably mounted in the vats 1 and are rotated by driving mechanism (not shown) to pick up and feed to carrying 'tapes or wet felts 6, 8 and 9, respectively, the digested or commi-nuted material in the vats 1. The carrying tapes 6, 7,

8 and 9 are mounted to travel over the couch 1 rolls 11, '12, 13 and 14, respectively, felt rolls 15 and jack rolls 16.

.The herein described paper making machine difi'ers from the customary multi-cylinder paper making machine in that each of the cylinder molds is, equipped with a separate wet felt or carrying tape instead of having one wet felt common to all the cylinder molds. Each of the cylinder molds is equipped with a well known type of deckling device, so that the width of the sheet can be controlled. at

will. As the structure of the papermaking machine, per se, forms no part of the present The sheets 19, 20, 21 and 22 are formed on cylinder molds 2, 3, 4 and 5 respectively and are removed by wet felts 6, 7, 8' and 9 "and couc'h-rolls 11, 12, 13 and 14 respectively.

Any desired number of cylinder molds and cooperating wet felts may lge used. As a preferred embodiment of the mvention. there is shown a multi-cylinder paper making mavchine having four cylinder molds and four wet felts, the cylinder molds 2 and 5 being arranged to produce sheets19 and 22 of the same width, as indicated in Fig. 5, .and cylinder molds 3 and 4 being arran ed to produce.

sheets '20 and 21, respective y, of different widths, as shown in Fig. 4. The sheet'19 carried on wet felt 6 is fed in longitudinal alignment with the sheet 20 carried on wet felt 7 and the sheet 19 as shown in Figures 1 and 3 is fed by the wet felt 6 into super osed position over the sheet 20 on the wet elt7, so that the longitudinal center lines of the two sheets 19 and 20 coincide. The wet felt 7 conveys the'two sheets 19 and 20 into superposed position over the sheet 21 carried on wet felt 8 so that the longitudinal center lines of the 3 sheets coincide as shown in Figure 4. The wet felt 8 conveys the'three sheets 19, 20 and 21 into superposed position on the sheet 22 carried on wet felt 9, so that the 101i tudinal center lines of the 4 sheetscoinci e as shown in Figure 5.

It will be noted that the sheets 'made by each cylindrical mold cooperating with the couch rolls and wet felts of each unit of the multi-cylinder paper making machine are fed in longitudinal alignment and when superposed one over the other are positioned so that the longitudinal center lines thereof coincide.

The resultant four-ply laminated-sheet is' fed by the wet felt 9 over the suction roll.25 which functions to remove some of the excess moisture from the laminated sheet. From the suction roll the four-ply laminated sheet is fed by the wetfelt 9 between pressing rolls 26, 27. The pressing roll 26 is shaped to conform with the desired contour of the finished product. In the instant case the roll 26 is of circular cross section at the mid thickened portion transversely of the length of the sheet to the sides of'the laminated Preferably, the laminated sheet is assed from the pressing rolls 26, 27 over the rying rolls 28, 29, 30 and 31. From the drying rolls the sheet may be fed to a cutting machine where it is slit longitudinally along the thickened portion 32 and the resultant laminated sheets may be wound intorolls for subsequent treatment or may be fed directly to a roofing machine where they are saturated with asphalt, pitch or the like, surfaced with granular or mineral matter, and-then severed transversely to form tapered or thick butt shingles 35 of the shape shown in Fig. 7 If desired, the individual sheets may be saturated with asphalt or other waterproofing material and then united as described herein, so that the asphalt or other waterproofing material aids in maintaining the bond between the individual sheets.

While there is shown and described herein as a preferred embodiment of the invention a process that produces a laminated strip having a longitudinal center portion of maximum thickness and of gradually diminishing thickness transversely of the length of the sheet from the maximum thickened portion, it will be understood that this invention is not limited thereto. For example, the paper makingmachine may be arranged to form a sheet having -a plurality of longitudinal thickened portions and being of gradually diminishing thickness transversely of the length of the sheet extending from the thickened portions of the sheet by feeding sheets of different widths in suitable relation to produce such laminated sheet and passing such sheet through pressing rolls corresponding with the contour of the desired laminated sheet.

It will 'be noted that the finished tapered shingle formed by cutting the laminated sheet transversely of the length of the sheet hast the top and bottom laminae thereof of the same length and the intermediate laminae of varying length.

While a preferred embodiment of the invention has been shown and described herein, it will be understood that various changes in the details thereof may be made without departing from the spirit of the invention, and therefore, this invention is not to be limited to the disclosure herein but only by the scope of the appended claims.

I claim:

1. In the process of producing waterproof weatherproof surfacing material suitable for roofing purposes the steps which comprise uniting a plurality of wet fibrous sheets of different widths, drying said sheets to form a substantially homogeneous strip, and waterproofing said strip.

2. The process of producing waterproof weatherproof surfacin material suitable for roofing purposes whic comprises placing a plurality of wet fibrous sheets of different widths in superposed relation, unitin said sheets to form a felt base of varying thic ness, removing excess moisture from said felt base and saturating said felt base with waterproofing material.

3. The process of producing waterproof weatherproof surfacing material suitable for roofing purposes which comprises simultaneously making a plurality of wet fibrous sheets of different widths, placing said sheets in longitudinal superposed relation, uniting said sheets to form a felt base of varying thickness, drying said felt base to form a substantially homogeneous felt and saturating said felt with bituminous material,

4. The process of producing waterproof weatherproof surfacing material suitable for roofing purposes which comprises placing a weatherproof surfacing material-suitable for.

roofing purposes which comprises simultaneously making four sheets, three of said sheets being of different widths, superposing said sheets so that the top and bottom sheets are of the same width and said sheets are in longitudinal alignment with the longitudinal center lines coinciding, uniting said sheets to form a surfacing material of varying thickness, and severing the resultant united sheet along the longitudinal center line to form a strip of surfacing material of progressively a decreasing thickness transversely of the length of said united sheets.

6. In the process of producing tapered shingles, the steps which comprise placing a plurality of wet fibrous sheets of different widths in superposed relation, uniting and drying said sheets-to form a substantially" homogeneous strip having one surface thereof inclined with respect to the opposite surface transversely of its length, saturating with bituminous material and surfacing said stri 7. The process of producing tapered shingles which comprises simultaneously making a plurality of wet fibrous sheets of different widths, superposing said sheets in longitudinal alignment, uniting and drying said sheets to form a substantially homogeneous strip having one surface thereof inclined with respect to the opposite surface transversely of its length, saturating said strip with bitu-- minous material, surfacing said strip and severing said stri transversely of-its length to form tapered s ingles.

8. The process of producing tape-red shinles which comprises simultaneously makingfour wet fibrous sheets, three of said sheets being of different widths, superposing. said sheets in longitudinal alignment with the longitudinal center lines of said sheets coinv ciding and the top and bottom sheets being of the same width, uniting said sheets and removing the excess moisture therefrom, severing the resultant strip along the longitudinal center line, saturating and surfacin the severed resultant strips and cutting said resultant stripstransversely to form tapered shingles.

9. A strip of substantially homogeneous surfacing material suitable for "roofing pur-' poses formed from a lurality of wet fibrous sheets of different wi ths and saturated with waterproofing material. p 0

10. A strip of substantially homogeneous surfacing material suitable for roofintg pur poses formed from a plurality of wet brous sheets of different widths in superposed relation united by pressure and saturated with bituminousmaterial.

11. A laminated strip of substantially homo eneous surfacing material suitable for roo g purposes, havin laminae in longitudinal ahgnment and o successively lesser widths andsaturated with Waterproofing materia 12. A four-ply laminated strip of surfacing material suitable for roofing purposes, three of the laminae being in longitudinal alignment and of successively lesser widths and the fourth lamina being substantially of the same width as the widest lamina and serving as one of the outer layers of the strip. 7 13. A tapered shingle strip of substantially homogeneous fibrous composition suitable for roofing purposes comprlsing a plurality of united wet fibrous sheets of different widths in superposed relation which has been dried and saturated with waterproofing material.

a 14. A tapered shingle strip of substantial- 1y fibrous composition suitable for roofin purposes comprising a plurality of sheets 0 successively lesser width and two sheets of substantially the same width, said two sheets serving as the outer surface layers of said strip, all of said sheets being united in superposed longitudinal relation. 15. A tapered shingle strip of-substantially homogeneous fibrous composition compris- 7 ing a plurality of sheets of successively lesser widths and two sheets of substantially the same width, said two sheets serving "as the outer surface layers of said strip, all of said sheets being united in superposed longitudinal relation, said strip bein saturated with bituminous material and sur aced. 16. A tapered laminated shingle having laminae of diflt'erent lengths united by pressure to form a homogeneous structure and saturated with bituminous material.

17. A tapered laminated shingle having laminae of different lengths and two laminae of substantially the same len h, said two laminae serving as the top an bottom surfaces of said shingle. h In] witness whereof, I have hereunto set my an HARRY A. EMERY.

I CERTIFlCATE 0F CORRECTION.

Patent No. 1,852,006. Aprils, 1932.

HARRY ALLEN EMERYQ It is hereby certified that error appears in the printed specification of the abore numbered patent requiring correction as follows: Page 4, line 28, claim 14, before the word "fibrous" insert the word homogeneous; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 5th day of July, A. D. 1932.

M. J. Moore,

(Seal) Acting Commissioner of Patents. 

